Woven pile fabrics

ABSTRACT

D R A W I N G A PILE FABRIC HAVING A BASE FORMED OF GROUND WARPS ARRANGED IN A PAIR OF BANKS INTERWOVEN WITH SUCCESSIVE GROUPS OF WEFTS, AND EACH GROUP OF WEFTS INCLUDING A PULRALITY OF PAIRS OF WEFTS. THE RESPECTIVE BANKS OF WARPS EXTEND IN OPPOSITION TO EACH OTHER SUCCESSIVELY OVER AND UNDER THE SUCCESSIVE GROUPS OF WEFTS WITH THE WARPS CROSSING EACH OTHER ONLY AT THE JUNCTURE OF ADJACENT GROUPS OF WEFTS, AND WEFTWISE ROWS OF SUBSTANTIALLY U-SHAPED PILE TUFTS ARE LOOPED BENEATH ONLY ONE PAIR OF WEFTS IN EACH RESPECTIVE GROUP.

Feb. 13, 1973 E. F. CLARK WOVEN FILE FABRICS Filed Nov. :3, 1971 UnitedStates Patent G 3,716,078 WIJVEN PILE FABRIC Eugene F. Clark, deceased,by Ursa W. Clark, heir, Eden, N.C., assignor to Fieldcrest Mills, Inc,Eden, N.C. Filed Nov. 3, 1971, Ser. No. 195,293 Int. Cl. DOSd 27/16 US.Cl. 139-399 10 Claims ABSTRACT OF THE DISCLOSURE This inventiongenerally relates to pile fabrics such as are used for carpets and rugs,and more especially, to improved pile fabrics of the Axminster type.

It is an object of this invention to provide a pile fabric of simpleconstruction which can be produced at high speeds on a spool-type loomwithout removing the spools from the usual conveyor chain therefor, andwherein the particular construction of the fabric contributes toeffective support for the pile tufts both during use and during weavingof the pile fabric.

It is a more specific object of this invention to provide a pile fabrichaving a base formed of ground warps arranged in a pair of banksinterwoven with successive groups of wefts with each group of weftsincluding a plurality of pairs of wefts, and the respective banks ofwarps extending in opposition to each other succesively over and underthe successive groups of wefts and crossing each other only at thejuncture of adjacent groups of wefts, and weftwise rows of substantiallyU-shaped pile tufts looped beneath only one pair of wefts in eachrespective group.

Some of the objects of the invention having been stated, other objectswill appear as the description proceeds, when taken in connection withthe accompanying drawings, in which:

FIG. 1 is a schematic perspective view of a portion of a preferredembodiment of the improved fabric, with portions broken away and showingthe opposing selvages thereof, with a few of the warpwise rows of tuftsomitted for purposes of clarity;

FIG. 2 is a warpwise vertical sectional view through the fabric takensubsantially along line 2-2 in FIG. 1;

FIG. 3 is a weftwise vertical sectional view taken substantially alongline 3-3 in FIG. 1;

FIG. 4 is a fragmentary warpwise vertical sectional view similar to FIG.2, but showing a second embodiment of the fabric; and

FIG. 5 is another fragmentary warpwise vertical sectional view similarto FIG. 2, but showing a third embodiment of the fabric.

Referring more specifically to the drawing, the pile fabric of thisinvention comprises a base or backing fabric formed of chain or hinderground warps arranged in a pair of banks 10, 11 interwoven withsuccessive groups of wefts. Each group of wefts includes a plurality ofsuccessive pairs of wefts, preferably in the form of a first pair ofwefts 12, 13 and a second pair of wefts 14, 15. In FIG. 1, foursuccessive groups of wefts are shown indicated at G, G-1, G2 and G-3.The respective banks of ground warps 10, 11 extend in opposition to eachother over and under the successive weft groups G, G-l, 6-2,

G3 with the warps 10, 11 thereby extending between the wefts only at thejuncture of adjacent weft groups. Thus, there are no ground warpsextending between any of the wefts 12-15 within each respective group.Stated otherwise, the ground warps in bank 10 extend over the weftgroups G-l, G-3 and under the weft groups G, G-2, and the ground warpsin bank 11 extend under the weft groups G-ll, G3 and over the weftgroups G, G-Z. It follows, therefore, that one bank of warps is disposedunder alternate groups of wefts and above intervening groups of weftswith the other bank of warps being disposed above said alternate groupsof wefts and under said intervening groups of wefts.

The fabric includes a pile face in the form of weftwise rows ofsubstantially U-shaped pile tufts 20. As shown in FIGS. 1 and 2 there isa single weftwise row of tufts for each group of wefts and the tufts ofeach weftwise row have their lower bights 20 looped beneath only one ofthe pairs of wefts in each respective group. In this instance, the tufts20 in each weftwise row are looped under the respective first pair ofwefts 12, 13 only, thus providing one of the second pairs of wefts 14,15 between each warpwise adjacent pair of substantially U-shaped tuftswith the legs of the tufts 20 projecting upwardly between adjacent firstand second pairs of wefts substantially throughout the length of thefabric.

Any desired number of chain warps may be provided between adjacent pairsof warpwise rows of tufts 20. As shown in FIGS. 1 and 3 by way ofexample, a group of four chain warps; i.e., two chain warps 10 from onebank and two chain warps 11 from the other bank is provided between eachadjacent pair of warpwise rows of tufts 20.

Although the chain warps of the fabric are disposed entirely above andentirely beneath the fabric base, except where they extend betweenadjacent groups of wefts, the wefts of the fabric may be disposed in acommon plane substantially parallel with opposite faces of the base, orsome of the wefts may be in a different plane from others of the weftsas desired. In this regard, in the first embodiment of the fabric, itwill be observed with particular reference to FIGS. 2 and 3 that the twowefts 12, 13 of the first pair in each group are disposed one above theother, and the two wefts 14, 15 of the second pair in each group aredisposed side by side or one in front of the other.

In the second embodiment of FIG. 4, the elements of the fabric bear thesame reference characters as in FIGS. 1-3 with the letter a addedthereto to avoid repetitive description. It will be observed that theportion of fabric shown in FIG. 4 differs from that shown in FIGS. 1-3only in that all of the wefts 12a-15a are disposed in a single plane;i.e., they are disposed in a common plane substantially parallel withthe upper and lower surfaces of the base. Such an effect may be producedby weaving the fabric of FIG. 4 with the chain warps and the pile yarnsunder somewhat lesser tension than is the case in weaving the fabricshown in FIGS. 1, 2 and 3.

In the third embodiment of the fabric shown in FIG. 5, the elements ofthe fabric bear the same reference characters as in FIGS. 1-3 with theletter b added thereto to avoid repetitive description. The portion ofthe fabric shown in FIG. 5 differs from those of FIGS. 1 3 and FIG. 4only in that one of the wefts of each pair is disposed above the otherweft of the corresponding pair in each instance; i.e., the two wefts ofeach pair 12b, 13b and 14b, 15b in each group are disposed one above theother. The yarns of which the warps, wefts and pile tufts are formed, ineach embodiment, may be conventional weights and constructions and,therefore, need not be further described.

Referring again to the first embodiment of the fabric shown in FIGS. 1,2 and 3, it will be observed in FIG. 1, in particular, that the fabricthere shown is provided with novel selvage constructions at oppositewarpwise side edges thereof. Such selvage constructions may be providedfor all three embodiments of the fabric and may be formed on a loomutilizing two side by side weft needles or inserters having separateweft yarn supplies. Each weft inserter may be of the type generally usedon an Axminster loom. Accordingly, an illustration of the weft insertersis deemed unnecessary.

It will be observed in FIG. 1 that the left-hand selvage is in the formof a plurality of hairpin-like selvage loops 21, 22 alternately arrangedwarpwise of the fabric and formed integral with and interconnecting thetwo wefts of the respective and first and second pairs 12, 13; 14, ofeach group G, G-l, 6-2, 6-3. A common selvage yarn 23 is threadedthrough, and interconnects all of, the selvage loops 21, 22 at thecorresponding warpwise side edge of the fabric.

The right-hand selvage of the fabric, as shown in FIG. 1, also is formedof loops of the wefts 12-15, including a plurality of first weft selvageloops 24 which alternate with respect to a plurality of second weftselvage loops 25. Although the first weft loops 24 are shown extendingoutwardly from the adjacent selvage warp 111 a greater distance than thesecond left loops 25, it is apparent that all of the weft loops mayextend outwardly the same distance or the second loops 25 may extendoutwardly further than the first weft loops 24, as desired.

More specifically, it will be observed that the lefthand portion of thecentermost first weft selvage loop 24 in the right-hand upper portion ofFIG. 1 is integral with weft 13 in weft group G-1 and extends across theweftwise plane of the second pair of wefts 14, 15 in the same weft groupG-1. The latter weft selvage loop 24 then extends into the next adjacentweft group G-2 on one side of weft group G-1 and is integral with theweft 12 of the first pair in the weft group G-Z. Similarly, it will beobserved that one of the second weft selvage loops 25 is integral withweft 15 in weft group G-1 and extends across the weftwise plane of thefirst pair of wefts 12, 13 in the next adjacent group 6-2. The latterloop 25 then extends into weft group G-2 and is integral with the weft14 of the second pair in weft group 6-2.

The weft selvage loops 24, 25 which are integral with the respectivewefts 12, 14 in group G-1 extend in the opposite direction from thoseWeft selvage loops which are integral with wefts 13, 15 in the same weftgroup G-1, and the latter weft selvage loops extend into the nextadjacent weft group G disposed on the other side of weft group G-1, andare formed integral with the respective wefts 13, 15 in group G. Thus,the bight of each first weft loop 24 extends across the weftwise planeof a respective second pair of wefts 14, 15, in each instance, and thebight of each second weft selvage loop 25 extends across the weftwiseplane of a respective first pair of wefts 12, 13, in each instance.

All three embodiments of the fabric have similar advantages, as will bementioned with respect to the fabric of FIGS. 1-3. In this regard, itshould be noted that, since none of the warps 10, 11 extend between anyof the wefts 12-15 within each group, it is apparent that there need beno warp shed change during the weaving of each portion of the fabricembraced by any one of the groups of wefts, such as the groups G, G-l,G-2, G-3 of FIG. 1. Thus, both pairs of wefts 12, 13; 14, 15 in eachgroup may be inserted in the warp shed and during a single pick of theloom, and a corresponding weftwise row of substantially U-shaped piletufts also may be formed during the corresponding pick of the loom.Also, the effect of a two-shot, double-Weft fabric construction isachieved, although the basic fabric construction is essentially asingle-shot weave; i.e., all four wefts 12-15 of each group are disposedin a single channel defined by the warp banks 10, 11 between successivepoints at which they extend between the wefts. The second pairs of wefts14, 15 not only aid in supporting the adjacent weftwise rows of tufts 20looped beneath the adjacent first pairs of wefts 12, 13, but they alsoare useful in supporting the tufts 20 during the weaving operation, asthe usual loom reed advances the wefts 12-15 of each group duringbeat-up of the reed to push the corresponding group of wefts forwardlyover the usual noseboard during the formation of the correspondingweftwise row of pile tufts 20.

In the drawing and specification, there have been set forth preferredembodiments of the invention and, although specific terms are employedthey are used in a descriptive and generic sense only and not forpurposes of limitation.

That which is claimed is:

1. A pile fabric comprising a base consisting of ground warps arrangedin a pair of banks interwoven with wefts, said wefts consisting ofsuccessive groups of wefts with each group of wefts including aplurality of pairs of wefts, and the respective banks of warps extendingin opposition to each other successively over and under said successivegroups of wefts and crossing each other only at the juncture of adjacentgroups of wefts, and weftwise rows of substantially U-shaped pile tuftslooped beneath only one pair of wefts in each respective group.

2. A pile fabric according to claim 1, wherein the two wefts of one ofsaid pairs in each group are positioned warpwise one in front of theother in at least a portion of the fabric, and wherein the two wefts ofanother pair in each group are positioned one above the other in saidportion of the fabric.

3. A pile fabric according to claim 2, wherein said tufts are looperbeneath only said other pair of wefts in each group.

4. A pile fabric according to claim 1, wherein said pairs of wefts ineach group extend in a single plane in at least a portion of the fabric.

5. A pile fabric according to claim 1, wherein the two wefts of each ofsaid pairs in each group are disposed one above the other in at least aportion of the fabric.

6. A pile fabric according to claim 1, including a selvage on one edgeof the fabric formed of loops of said wefts and wherein one of the weftsof each pair forms a loop extending from one of said groups to the nextadjacent group on one side thereof and which loop is integral with arespective one of the wefts in said next adjacent group, and wherein theother weft of each pair in said one of said groups forms another loopextending therefrom to the next adjacent group on the other side of saidone of said groups nad which other loop is integral with a respectiveone of the wefts in the last-mentioned next adjacent group.

7. A pile fabric comprising a base consisting of ground warps arrangedin a pair of banks interwoven with wefts, said wefts consisting ofsuccessive groups of wefts, with each group of wefts consisting of afirst pair of wefts and a second pair of wefts, and the respective banksof warps extending in opposition to each other successively over andunder said successive groups of wefts and crossing each other only atthe juncture of adjacent groups of wefts, and weftwise rows ofsubstantially U-shaped tufts looped under only one of the pairs of weftsin each group with the legs of the tufts projecting upwardly betweenadjacent first and second pairs of wefts.

8. A pile fabric according to claim 7, including a selvage on one edgeof the fabric and comprising a first selvage loop integral with andconnecting one of the wefts of the first pair in one group to one of thewefts of the first pair in an adjacent group, and a second selvage loopintegral with and connecting one of the wefts of the second pair in saidadjacent group, wherein the first selvage loop extends across theweftwise plane of both of the 5 wefts of the second pair in said onegroup, and wherein References Cited the second selvage loop extendsacross the weftwise plane UNITED STATES PATENTS of both of the Wefts ofthe first pair in said adjacent 716 519 12/1902 Clark 139 401 group.

9- A pile fabric according to claim 8, including a 5 g selvage on theother edge of the fabric formed of hair- 5 41 5/1962 i g z'g 139 4O2pin-like selvagc loops integral with an interconnecting both Wefts ofeach respective pair HENRY S. J-AUDON, Primary Examiner 10. A pilefabric according to claim 9, including a common selvage yarn extendingthrough all of said hair- 10 U8. Cl. X.R.

pin-like selvage loops. 139-402 3, 716,078 Dated February 13, 1973Patent No.

lnventofls) Eugene F. Clark, deceased, by .Ursa W. Clark, Heir It iscertified that error appears in the above-identified patent and thatsaid Letters Patent are-hereby corrected as shown below:

IN THE CLAIMS:

Column-4, Line 35, Claim 3, "looper" should be --looped-; v same column,Claim 6, Line 52, "had should be --and--; same column, Claim 8, Line 74,"0nd" should be --one-; same column same Claim, Line 74, after "said"insert --one group to one of the wefts of the second pair in said Column5, Line '7, "an" should be -and-- Signed and sealed this 3rd day of July1975.

(SEAL) Attestz EDWARD M.PLETCHER,JR. j Rene Tegtmeyen Attesting OfficerActi Commissioner of Patents FORM Po-1'o5o (10-69) USCOMM-DC wan-P69U.S. GOVERNMENT PRINTING OFFICE i969 O-356334

